Case Study · Thermal Imaging
Thermal Imaging: Micro-Coax Impedance Crisis Recovered, Partnership Saved
Joint root-cause analysis traced the failures to a spec-versus-test mismatch, driving updated specs and a replacement order for all 1,296 defective micro-coax assemblies.
Belgium · 2020 · Thermal Imaging harnesses
1,296 of 2,000 units recovered
AWG#40 micro-coax
Root cause + spec re-defined
Background
A European thermal imaging OEM ran a beta production series built on AWG#40 CABLINE-VS 1:1 100mm micro-coaxial cable assemblies. High-impedance defects triggered a critical production halt.
The Challenge
Of 2,000 micro-coax assemblies, 1,296 failed due to high impedance. The failures led to order cancellation, a demand for refunds, and a major trust deficit with the customer.
Our Solution
We halted production immediately and ran a joint technical analysis with the customer's engineering team, tracing the root cause to a mismatch between the specification definition and the testing method. We updated the specifications, issued new test reports, built new samples, and processed a replacement order for the defective units.
The Result
We resolved the quality complaint and secured a replacement order for all 1,296 defective units. The long-term partnership held despite the severe initial defect rate.
Program Specifications
| Gauge | AWG#40 |
|---|---|
| Cable | CABLINE-VS 1:1, 100mm |
| Defective Units | 1,296 of 2,000 |
| Replacement Units | 1,296 |